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Defence said 1274 voted at polling stations in the exercise area and 1371 were transported to polling stations in Port Augusta, Whyalla, Port Pirie and Kadina.

But the emails to the AEC say the number of personnel taking part was around 9000.

Personnel came from not only Townsville but Darwin, Brisbane and Sydney.

The AEC was told in one email, written by a member of the exercise planning team Major Jeremy Webb on March 30, special voting facilities would be needed because "the nature of the exercise is such that personnel will be deployed in the field, within a tactical scenario, that will prevent them from being able to present to an election booth and/or post office during the two-month timeframe (June-July)".

The final email dated April 6 said the AEC would "work through some options" for the July 2 election.

Voting facilities were rolled out across the exercise area.

But soldiers have told AAP of problems with accessing absentee ballot papers for Herbert, long travel times to get to booths and long waits to vote.